101609-3730 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016093730

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101609-3730 1016093730

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Service parts 101609-3730 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8860

3. GOVERNOR 105411-2640

4. SUPPLY PUMP 105210-6260

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6260

11. Nozzle and Holder 6221-13-3500

12. Open Pre:MPa(Kqf/cm2) 23.0{235}

13. NOZZLE-HOLDER 105048-3560

14. NOZZLE 105017-1960

15. NOZZLE SET

Include in #1:

101609-3730 as INJECTION-PUMP ASSEMBLY

Include in #2:

104265-4061 as _

Cross reference number

ZEXEL 101609-3730 1016093730

Zexel num

Bosch num

Firm num

Name

101609-3730

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-3420

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.6 3.55 3.65

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 9.2

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 117 116 118

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Boost pressure kPa 152 152

Boost pressure mmHg 1140 1140

Injection quantity adjustment_02

Adjusting point C

Rack position 6.4+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 13.5 12.3 14.7

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point D

Rack position 10.85++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 125 120 130

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R1-2.1

Boost pressure kPa 40 37.3 42.7

Boost pressure mmHg 300 280 320

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1(10.35 )

Boost pressure kPa 139 139 139

Boost pressure mmHg 1040 1040 1040

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL (5)Set idle sub-spring
----------
K=14 BCL=2.1+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)When pump speed set at bb (3)Set the speed at cc (at delivery) (4)Stopper bolt setting
----------
aa=80mm bb=750r/min cc=900r/min
----------
a=8deg+-5deg b=9deg+-5deg c=21deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Rack position bb, pump speed cc (3)Normal
----------
aa=33.6mm bb=1-0.2mm cc=0r/min
----------
a=27.5deg+-5deg b=(55deg)

Timing setting

(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=13deg
----------
a=(50deg)

Information:

Start By:a. remove rocker shaft assembly and push rodsb. remove exhaust manifoldc. remove air cleaner groupd. remove aftercooler The procedure which follows was done on a 3306 Engine. 1. Remove bolts (1), mounting bracket and pipe assembly (2) and lifting bracket (3) from the cylinder head assembly. 2. Remove temperature sending unit (5) from elbow (4).3. Loosen clamp (6), and remove the bolts that hold elbow (4) to the water pump and cylinder head assembly. Remove the elbow and gaskets from the engine. 4. Install Tool (A) on the cylinder head assembly as shown, and fasten a hoist on it.
Do not set the cylinder head assembly on a flat surface because of possible damage to the fuel injection nozzle tips.
5. Remove all bolts (7) and (8) that hold the cylinder head assembly to the cylinder block. Remove the cylinder head assembly. The weight of the cylinder head assembly (3304) is 64 kg (142 lb). The weight of the cylinder head assembly (3306) is 95 kg (210 lb). 6. Remove head gasket (9), water seals (11) and the O-ring seal from dowel (10). Remove spacer plate (12), the spacer plate gasket and the O-ring seal from dowel (10).Install Cylinder Head Assembly & Spacer Plate
The procedure which follows was done on a 3306 Engine.
When the cylinder head assembly is removed a new spacer plate gasket and a new cylinder head gasket must be installed. Do not use any adhesive or other substances on these gaskets or the surfaces they contact.
1. Thoroughly clean the spacer plate, cylinder head and cylinder block surfaces. If dowel (1) was removed for any reason, install a new dowel until it extends 16.0 0.5 mm (.63 .02 in) from the cylinder block.2. Install the O-ring seal on dowel (1) against the cylinder block. Install spacer plate gasket (2) and spacer plate (3) on the cylinder block.3. Check the cylinder liner projection height. See topic, "Install Cylinder Liners". 4. Install the O-ring seal on top of the spacer plate around dowel (1). Install cylinder head gasket (4) and water seals (5). 5. Install Tool (A) on the cylinder head assembly as shown. Fasten a hoist to it. Put the cylinder head assembly in position on the engine.6. Put 2P2506 Thread Lubricant on all the cylinder head bolts. Install them until they are finger tight. Remove Tool (A) from the engine. 7. Install push rods (6). Make sure they are installed in their original locations. Be sure the push rods are in position in the valve lifters.8. Loosen the adjusting screws on the rocker arms for valve clearance. This will prevent a bend valve or push rod during installation of the rocker shaft assembly.9. Install a new O-ring seal in the rear rocker arm support bracket.10. Put 2P2506 Thread Lubricant on all of the rocker shaft bolts except the one that goes through the rear rocker arm support bracket.11. Put rocker shaft assembly (7) in position on the cylinder head assembly. Make sure the dowels in